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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old February 20th, 2017, 21:42   #1
Strider17
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Default MK5 2.0CR to MK5 2.5L Swap DIY - WIRING GURUS NEDED!!

Hello everyone,

(i am making this a FULL DIY so ALL help is MUCH appreciated.

just a little background on my experiences.

I work on MK4s and MK5s on a daily basis. I have done AUTO to 5Spd swap on Mk4s, gas to diesel on my MK5 GTI, but i have never done an MK5 swap of any sort.

Back when i did my mk4 GTD swap everything was straight forward EXCEPT the wiring. Now i will be doing a GAS to DIESEL on my mk5 wagons i picked up so Ill need help with the wiring.

I can do ALL mechanical work but when it comes to wiring i am completely lost...so bare with me.


Vehicles i picked up:

Crashed - 2009 Jetta Sporstwagen 2.0L CR 6Spd - Made in 06.09
Good - 2009 Jetta Sportwagen 2.5L 5Spd - Made in 06.08


Here is what ill be doing for the swap as of now:

Taking out 2.5L engine/tranny, Engine Harness, ECU, Cluster, Gas Pedal, Gas Tank.

Everything I have taken out from the GASSER will be swapped in for the DIESEL Parts.

Now, as for the wiring.

I would like to be able to just swap over some pins under wiper plenum, ECU connector and under the steering wheel.

I dont want to take out the WHOLE dash and swap every piece of wiring in the wagons. The 2.5L also came with a FULL FIS cluster and a MFSW (multifunction steering wheel) ....i have talked to a member on here already about the cluster swaps but it seems like i would need a FULL FIS DIESEL cluster for everything to work.

I was just going to swap the ecu, cluster and keys from the diesel into the 2.5L and call it a day for now. I know the FULL FIS functions will be lost since the diesel cluster is only an MFA cluster but will i have any other issues/coding to do?
Also will the MFSW buttons work with a MFA diesel cluster installed?


I will post pictures of both cars and ALL the progress. I also have VCDS and vag commander so i can recode or post anything thats needed.


As for now, if there is anyone with wiring diagrams or bentley manuals that can help me out with the wiring, it would be greatly appreciated

Last edited by Strider17; February 20th, 2017 at 22:09.
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Old February 21st, 2017, 07:16   #2
jetta ,97
 
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Quote:
Originally Posted by Strider17 View Post

I was just going to swap the ecu, cluster and keys from the diesel into the 2.5L and call it a day for now. I know the FULL FIS functions will be lost since the diesel cluster is only an MFA cluster but will i have any other issues/coding to do?
Also will the MFSW buttons work with a MFA diesel cluster installed?

Like I told you in email your ABS coding will get lost and will not be able to recover it because VIN will not match in cluster and ECU vs vehicle , TDI has different VIN form 2.5.

2009 has long Coding for ABS and even Ross-Tech can not help you on this , this coding goes online with ODIS and that is how gets coded, but since you have vehicle one VIN and cluster/ECU different VIN i do not think even online coding will be able to do this.

There is no cheap way around this , best and only one right solution is to put High Line TDI cluster and program ECU and TDI cluster to 2.5 car.

For MFSW buttons, they may work or not, cluster control a lot when it comes to that.
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Last edited by jetta ,97; February 21st, 2017 at 07:18.
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Old February 21st, 2017, 07:47   #3
Strider17
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Jetta97:
What if I swapped the abs module from the diesel wagon into the gasser wagon, along with the ECU, cluster and keys. Will that work?

I will keep the highline cluster you mentioned in mind for sure.

Also, if I only swapped the ECU, cluster and keys from the diesel to the cluster and didn't program the abs module, is that something a dealership can do? Since it has to be coded through ODIS
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Old February 21st, 2017, 07:57   #4
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i am trying to find a cheaper alternative to keep the FULL FIS function in the 2.5L using a diesel cluster.
I have found one at a local scrap yard for 100 CAD. part number:

1K0920974N

jetta97. would it be possible to buy that one, and get it programmed with the ECU/ABS Module/Keys?

If not that cluster, what part number should i be looking for?
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Old February 21st, 2017, 16:24   #5
jetta ,97
 
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1K0920974N is USA MPh cluster.
You need to find 1K0920874N, to be in Kmh.
And once you find this one ,
I can get it programmed with the ECU/ABS Module/Keys.
__________________
I do any repair on all models,USED/NEW ECU and Cluster swap, Reprogramming Keys , Immobilizer Delete,Cluster LCD Dispay Repair -Clik here
I am trusted TDI Mechanic, VCDS
HEX+CAN
ECU TUNING-TDTUNING Authorized Dealer
MK6 Needle Sweep,MK5 with MK6 Cluster

Last edited by jetta ,97; February 21st, 2017 at 16:27.
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Old February 21st, 2017, 16:30   #6
Strider17
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I cant seem to find ANY ending with "N"

Im going to see the dealer and see if the part number has been updated.

Also, any ideas where these clusters were used in? which cars? I have cousins over in Europe so i might be able to get it from vehicles there.

thank you
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Old February 22nd, 2017, 06:29   #7
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In Europe they have one ending 874B,
You can use that one, but they not cheap in Europe at all.Much more then here.
__________________
I do any repair on all models,USED/NEW ECU and Cluster swap, Reprogramming Keys , Immobilizer Delete,Cluster LCD Dispay Repair -Clik here
I am trusted TDI Mechanic, VCDS
HEX+CAN
ECU TUNING-TDTUNING Authorized Dealer
MK6 Needle Sweep,MK5 with MK6 Cluster
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Old April 18th, 2017, 20:04   #8
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Progress Has Started

Blue Wagon is the DONOR
Black Wagon is the PROJECT

ripped apart the blue wagon
took apart the rear of the black wagon
made a new custom hitch for it
diesel tank, catback and new supesion/brake setup is going in











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Old April 18th, 2017, 20:05   #9
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Old April 18th, 2017, 20:07   #10
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Old June 5th, 2017, 15:35   #11
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Everything is in:

Wiring is the only thing that needs to be done

Here are the differences and what needs to be wired in or changed in the engine fuse box/ECU body connector

I have swapped over some of the fuses from the 2.5L fuse box to the TDI fuse box and used to TDI used box in the car


2.5L Fuse Box:




2.0 TDI Fuse Box:




Connector that runs on the TDI Engine Harness:





Connector that is suppose to plug into the engine harness plug (shown above)





Connector that runs on the wiring loom that connects to alternator/compressor to the fuse box *not sure what to do with this*



Connector that runs in the body harness in the engine bay *not sure what to do with this*



N75 Solenoid for Turbo - This needs to be wired in somehow...2.5L body harness doesnt have a connector for this - neither does the engine harness



This was the 2.5L O2 sensor - closer to engine
I just plugged in the TDI O2 Sensor into it....might need to be wired properly?

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Old June 5th, 2017, 15:44   #12
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These 2 connectors also need to be wired into the 2.5L body harness:
One connects to the downpipe - right after the first O2 sensor. The other connects on the exhaust manifold on turbo
Not sure what they are called.

Since this ECU/engine has the whole DPF/EGR deleted, the only wiring to be done is the first O2 sensor and these 2 connectors. Everything else is deleted and tuned out




This is the PCV connector. THis doesnt have a connector either - Needs to be wired in?




This connector is for the Fuel Pump beside the timing belt cover
This definitely needs to be wired in for the HPFP to work properly.
Not sure where to wire this in:




These 2 connectors are just opened and not sure what they were plugged into...they are located under the airbox...where the Radiator Fans plug in.
Not sure what they did or where they plug into:





Lastly, this is the plug that plugged into the 2nd O2 sensor after the CAT on the 2.5L downpipe. It is left open..not sure what to do with it:




Pretty much that is the differences i found...those connectors and wiring harness will need to be wired in.
I have found a TDICLUB member near me that is helping me with the wiring.

I also have the FULL body harness from the Donor TDI. Might be helpful figuring out the wiring

to be continued..
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Old June 8th, 2017, 20:21   #13
dieselherb1
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I'm also doing a CR swap but into MK5 PD car, but it was a DSG I'm installing a 6 speed. Everything is in now I'm having wiring issue. Engine module is not communicating with injection pump so will not start. then I'll have the issue of the clutch safety switch and reverse lights.
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Old June 10th, 2017, 08:17   #14
Strider17
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Quote:
Originally Posted by dieselherb1 View Post
I'm also doing a CR swap but into MK5 PD car, but it was a DSG I'm installing a 6 speed. Everything is in now I'm having wiring issue. Engine module is not communicating with injection pump so will not start. then I'll have the issue of the clutch safety switch and reverse lights.

can you document and post all the wiring you have to do? would help a lot with future swaps
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Old June 12th, 2017, 13:49   #15
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At this point no one is able or willing to help. Everything on the chassis side works fine, but engine module not connecting. I ordered a Bentley but it will be week or more.
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